Burner with Monitoring

ABSTRACT

An oxy-fuel burner with monitoring including a fuel passage terminating in a fuel nozzle, a primary oxidant passage terminating in an oxidant nozzle, one or more sensors including a nozzle temperature sensor for sensing at least one of an oxidant nozzle temperature and a fuel nozzle temperature and a position sensor for sensing a burner installation angle, and a data processor programmed to receive data from the sensors and to determine the presence or absence of an abnormal burner condition including a potential partial obstruction of at least one of the primary oxidant passage and the fuel passage based on an increase or decrease in at least one of the oxidant nozzle temperature and the fuel nozzle temperature, and to determine whether the burner is installed at a desired orientation with respect to at least one feature of the furnace based on the burner installation angle.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/026,309 filed on Mar. 31, 2016, which was a National Stage entry ofPCT/US2015/028284 filed on Apr. 29, 2015, which claims the priority ofU.S. Provisional Application No. 61/987,652 filed on May 2, 2014, eachof which is incorporated by reference herein in its entirety.

BACKGROUND

This application relates to an oxy-fuel burner, and in particular astaged oxy-fuel burner, configured with instrumentation to monitor thestatus and health of the burner, as well as burner operation and itseffect on the process, to perform real-time control of burner operationbased on data obtained from such monitoring, and to enable intelligentpreventative maintenance to be conducted no sooner than necessary butprior to a failure or unforeseen shutdown condition.

For conventional burner systems, furnace operators determine amaintenance schedule on past experience, or on a regular calendar basis.This frequently results in a maintenance schedule that is overlyaggressive, costing excess man hours and burner downtime, or is overlylax, failing to capture correctable burner issues before a failureoccurs.

Systems exist for limited monitoring of various burner parameters, butnone integrates this monitoring in a comprehensive way to enablepredictive maintenance. For example, some existing systems requireoptical access of a flame, temperature sensors to prevent overheating,or pressure sensors to monitor flame instability. But none monitorcombinations of parameters in a way that enables predictive maintenance.

SUMMARY

An oxy-fuel burner, and in some embodiments a staged oxy-fuel burner, asdescribed herein is configured with integrated sensors to measureseveral parameters that are useful in monitoring the health of theburner and in predicting the need for maintenance. For any oxy-fuelburner, these parameters may include, without limitation, separately orin combination, the inlet fuel pressure, temperature, and density, theinlet oxidant pressure, temperature, and density, the staging valveposition (for a staged burner), the fuel nozzle temperature, the oxygennozzle temperature, burner block temperatures at various locations, oneor more installation angles of the burner and/or burner block, therelative and/or absolute position of the burner with respect to otherfeatures of the furnace, charge or bath temperatures, and opticalemissions from the flame or the burner face. For a staged oxy-oilburner, those parameters may include one or more parameters, separatelyor in combination, including but not limited to the inlet oiltemperature, the inlet oil pressure, the atomizing oxidant (air oroxygen-enriched air or oxygen) pressure, the oxygen feed pressure, thestaging valve position, the lance tip or atomizing nozzle temperature,and the burner block temperature. This information collected from thesesensors can be used by operators/engineers directly, or by an automatedmonitoring and alerting system, to monitor the performance of theburner, to identify any maintenance needs of the burner, for example toschedule maintenance and improve the burner operation, and to detectburner system malfunctions.

Such instrumentation can be integrated into any burner, including aburner that uses one or more of gaseous fuel, liquid fuel, and solidfuel, and including a non-staged burner, a fuel-staged burner, anoxidant-staged burner, and a burner in which both fuel and oxidant arestaged. It is understood that for each type of burner, the type,position, and quantity of sensors can be customized to correspond to theoperational modes and parameters most relevant to that particularburner.

Various features are built into the burner so that the electronicmonitoring does not interfere with normal operation and maintenance ofthe burner. The instrumentation is also protected so that it willcontinue to function for long periods of time in the type of harshenvironments in which burners normally operate. In one embodiment, theelectronics are battery powered and transmit data wirelessly for ease ofinstallation and maintenance.

A burner with integrated sensors can be used as part of a system forremote tracking of burner parameters to enable real-time monitoring ofburner performance and to assist in predictive maintenance by detectingchanges in operation of the burner before a failure or shutdown occurs,such as is described in commonly owned U.S. patent application Ser. No.14/268,655 entitled “Remote Burner Monitoring System and Method” filedMay 2, 2014, which is incorporated by reference herein in its entirety.

Aspect 1: An oxy-fuel burner with monitoring, comprising: a fuel passageterminating in a fuel nozzle; a primary oxidant passage terminating inan oxidant nozzle; one or more sensors for sensing process dataincluding a nozzle temperature sensor for sensing at least one of anoxidant nozzle temperature and a fuel nozzle temperature; and a dataprocessor programmed to receive process data from the sensors and todetermine based on at least a portion of the received data the presenceor absence of an abnormal burner condition.

Aspect 2: The burner with monitoring of Aspect 1, wherein the dataprocessor is programmed to identify a potential partial obstruction ofat least one of the primary oxidant passage and the fuel passage basedon an increase or decrease in at least one of the oxidant nozzletemperature and the fuel nozzle temperature.

Aspect 2a: The burner with monitoring of Aspect 2, wherein the one ormore sensor is an oxidant nozzle temperature sensor for sensing theoxidant nozzle temperature, and wherein the data processor is programmedto identify a potential partial obstruction of the primary oxidantpassage based on an increase or decrease in the oxidant nozzletemperature.

Aspect 2b: The burner with monitoring of Aspect 2, wherein the one ormore sensor is a fuel nozzle temperature sensor for sensing the fuelnozzle temperature, and wherein the data processor is programmed toidentify a potential partial obstruction of the fuel passage based on anincrease or decrease in the fuel nozzle temperature.

Aspect 3: The burner with monitoring of Aspect 1 to 2b, wherein the dataprocessor is programmed to base its determination at least in part uponchanges in at least a portion of the received data with time.

Aspect 4: The burner with monitoring of any of Aspects 1 to 3, the oneor more sensors further including an oxidant pressure sensor positionedin the primary oxidant passage for sensing a primary oxidant pressure;wherein the data processor is programmed to identify a potential partialobstruction of the primary oxidant passage based on a change to theprimary oxidant pressure and at least one of the fuel nozzle temperatureand the oxidant nozzle temperature.

Aspect 5: The burner with monitoring of any of Aspects 1 to 3, furthercomprising: a secondary oxidant passage spaced apart at a fixed distancefrom the primary oxidant passage; and a staging valve for proportioningoxidant between the primary and secondary oxidant passages; the one ormore sensors further including a staging valve position sensor forsensing a staging valve position as indicative of the relativeproportion of oxidant being directed to the primary and secondaryoxidant passages; wherein the data processor is further programmed todetermine the presence or absence of a partial obstruction of theprimary oxidant passage based on the staging valve position and at leastone of the fuel nozzle temperature and the oxidant nozzle temperature.

Aspect 6: The burner with monitoring of any of Aspects 1 to 3, furthercomprising: a secondary oxidant passage spaced apart at a fixed distancefrom the primary oxidant passage; and a staging valve for proportioningoxidant between the primary and secondary oxidant passages; the one ormore sensors further including: an oxidant pressure sensor for sensingan oxidant pressure at one or more of upstream of the staging valve,downstream of the staging valve in the primary oxidant passage, anddownstream of the staging valve in the secondary oxidant passage; and astaging valve position sensor for sensing a staging valve position asindicative of the relative proportion of oxidant being directed to theprimary and secondary oxidant passages; wherein the data processor isfurther programmed to determine the presence or absence of one or moreof a partial obstruction of one of the primary oxidant passage and thesecondary oxidant passage and a sub-optimal staging valve position,based on the staging valve position and the oxidant pressure at one ormore of upstream of the staging valve, downstream of the staging valvein the primary oxidant passage, and downstream of the staging valve inthe secondary oxidant passage.

Aspect 7: The burner with monitoring of any of Aspects 5 to 6, furthercomprising: two pressure sensors, one positioned on either side of aflow restriction device in at least one of the fuel passage, the primaryoxidant passage, and the secondary oxidant passage, for sensing apressure upstream of the flow restriction device, a pressure downstreamof the flow restriction device, and a differential pressure across theflow restriction device as indicative of flow rate; wherein the dataprocessor is further programmed to determine the presence or absence ofan abnormal burner condition based on the differential pressure and oneof the pressures upstream and downstream of the flow restriction device.

Aspect 8: The burner with monitoring of any of Aspects 1 to 7, furthercomprising: a burner block having a hot face adjacent to the furnace;and a burner block temperature sensor for sensing a burner blocktemperature near the hot face; wherein the data processor is furtherprogrammed to receive data from the burner block temperature sensor andto determine the presence or absence of one or more of burner blockoverheating and flame asymmetry based on the burner block temperature.

Aspect 9: The burner with monitoring of any of Aspects 1 to 8, furthercomprising: a position sensor for sensing a burner installation angle,the position sensor being configured to sense one or more of a burnerpitch and a burner roll; wherein the data processor is furtherprogrammed to determine whether the burner is installed at a desiredorientation with respect to at least one feature of the furnace based onthe burner installation angle.

Aspect 10: The burner with monitoring of any of Aspects 1 to 9, furthercomprising: a unique identifier on a removable component of the burner;wherein the data processor is further programmed to use the uniqueidentifier to tag data for analysis purposes.

Aspect 11: The burner with monitoring of any of Aspects 1 to 10, furthercomprising: a data collector programmed to provide power to individualsensors only when data is to be collected, based on one or both of acombination of sensed data and a periodic schedule, and taking intoaccount the specific requirements of each of the individual sensors; atransmitter for wirelessly transmitting sensor data from the datacollector to the data processor; and a local power generation system forpowering the data collector, the sensors, and the transmitter.

Aspect 12: The burner with monitoring of any of Aspects 1 to 11, whereinthe oxidant passage is annular and surrounds the fuel passage.

Aspect 13: A method of determining an operating condition of an oxy-fuelburner including a fuel passage terminating in a fuel nozzle, a primaryoxidant passage terminating in an oxidant nozzle, and a burner blockhaving a face adjacent to the furnace, the method comprising: sensingburner parameters from one or more sensors selected from the groupconsisting of temperature sensors, pressure sensors, density sensors,flow sensors, position sensors, angle sensors, contact sensors,accelerometers, optical sensors, and combinations thereof; comparing thesensed parameters with expected values for each said burner parameter todetermine the presence or absence of a deviation in the burnerparameter; and determining the presence of an abnormal burner conditionbased on the presence of a deviation in one or more burner parameters.

Aspect 14: The method of Aspect 13, further comprising: sensing at leastone of an oxidant nozzle temperature and a fuel nozzle temperature;comparing the at least one nozzle temperature to a thresholdtemperature; and determining a potential partial obstruction of one ofthe oxidant nozzle and fuel nozzle based on an increase or decrease inthe at least one nozzle temperature.

Aspect 15: The method of Aspect 14, further comprising: sensing anoxidant pressure; and determining a potential partial obstruction of theoxidant nozzle based on the oxidant pressure and the at least one nozzletemperature.

Aspect 16: The method of Aspect 13 or 14, the burner further including asecondary oxidant passage spaced apart at a fixed distance from theprimary oxidant passage and a staging valve for proportioning oxidantbetween the primary and secondary oxidant passages, the method furthercomprising: sensing a staging valve position indicating the proportionof oxidant being directed to the primary and secondary oxidant passages;determining a potential partial obstruction of the primary oxidantpassage based on the staging valve position and the at least one nozzletemperature.

Aspect 17: The method of Aspect 13 or 14, the burner further including asecondary oxidant passage spaced apart at a fixed distance from theprimary oxidant passage and a staging valve for proportioning oxidantbetween the primary and secondary oxidant passages, the method furthercomprising: sensing an oxidant pressure from a location selected fromupstream of the staging valve, downstream of the staging valve in theprimary oxidant passage, and downstream of the staging valve in thesecondary oxidant passage; sensing a staging valve position indicatingthe proportion of oxidant being directed to the primary and secondaryoxidant passages; determining one or more of a potential partialobstruction of one of the primary oxidant passage and the secondaryoxidant passage and a sub-optimal staging valve position based on thestaging valve position and the oxidant pressure at one or more ofupstream of the staging valve, downstream of the staging valve in theprimary oxidant passage, and downstream of the staging valve in thesecondary oxidant passage.

Aspect 18: The method of any of Aspects 13 to 17, further comprising:sensing pressures at two locations, one on either side of a flowrestriction device in at least one of the fuel passage, the primaryoxidant passage, and the secondary oxidant passage; determining a flowrate from the pressures at the two locations; and determining thepresence or absence of an abnormal burner condition based on the flowrate and the pressure of at least one of the two locations.

Aspect 19: The method of any of Aspects 13 to 18, further comprising:sensing a burner installation angle, including at least one of a burnerpitch and a burner roll; and determining whether the burner is installedat a desired orientation with respect to at least one feature of thefurnace based on the burner installation angle.

Aspect 19a: The method of any of Aspects 13 to 19, wherein the oxidantpassage is annular and surrounds the fuel passage.

Aspect 20: An oxy-fuel burner with monitoring, comprising: a fuelpassage having a fuel nozzle at a tip end and a fuel inlet distal fromthe tip end; a primary oxidant passage surrounding the fuel passage; atemperature sensor positioned in the fuel nozzle at the tip end of thefuel passage for sensing a fuel temperature; a fuel pressure sensorpositioned near the fuel inlet for sensing a fuel pressure; and aninstrument enclosure for receiving data from the sensors.

Aspect 21: The burner with monitoring of Aspect 19 or 20 furthercomprising: a secondary oxidant passage spaced apart at a fixed distancefrom the primary oxidant passage; a staging valve for proportioningoxidant between the primary and secondary oxidant passages; an oxidantpressure sensor positioned upstream and/or downstream of the stagingvalve for sensing an oxidant inlet pressure; and a staging valveposition sensor for sensing a staging valve position as indicative ofthe relative proportion of oxidant being directed to the primary andsecondary oxidant passages.

Aspect 22: The burner with monitoring of Aspect 20 or 21, furthercomprising: a data processor for receiving data from the sensors,wherein the data processor is programmed to determine based on datareceived from one or more sensors the presence or absence of an abnormalburner condition or sensor malfunction.

Aspect 23: The burner with monitoring of any of Aspects 20 to 22,further comprising: a position sensor for sensing an installation angleof the burner and optionally parts that the burner is mounted to;wherein the installation angle of the burner is usable to furtherindicate whether the burner is installed at a desired orientation and/orslope with respect to the furnace.

Aspect 24: The burner with monitoring of any of Aspects 20 to 24,further comprising: a unique identifier on the primary oxidant passage;wherein the primary oxidant passage identifier is usable to tag data foranalysis purposes.

Aspect 25:The burner with monitoring of any one of Aspects 20 to 24, theinstrument enclosure comprising: a data collector programmed to providepower to individual sensors only when data is to be collected, based onone or both of a combination of sensed data and a periodic schedule, andtaking into account the specific requirements of each of the individualsensors; and a transmitter for wirelessly transmitting sensor data fromthe data collector to a data center.

Aspect 26: The burner with monitoring of Aspect 25, the instrumentenclosure further comprising: a local power generation system forpowering the data collector, the sensors, and the transmitter.

Aspect 27: An oxy-fuel burner with monitoring, comprising: a primaryfirst reactant passage terminating in a first reactant nozzle; a primarysecond reactant passage terminating in a second reactant nozzle; one ormore sensors including a temperature sensor for sensing a nozzletemperature of at least one of the reactant nozzles; and a dataprocessor programmed to receive data from the sensors and to determinebased on at least a portion of the received data the presence or absenceof an abnormal burner condition including a potential partialobstruction of at least one of the primary first reactant passage andthe primary second reactant passage based on an increase or decrease inat least one of the reactant nozzle temperatures; wherein one of thefirst and second reactants is a fuel and the other of the first andsecond reactants is an oxidant.

Aspect 28: The burner with monitoring of Aspect 27, wherein the one ormore sensor is a nozzle temperature sensor for sensing the firstreactant nozzle temperature, and wherein the data processor isprogrammed to identify a potential partial obstruction of the primaryfirst reactant passage based on an increase or decrease in the firstreactant nozzle temperature.

Aspect 29: The burner with monitoring of Aspect 27 or 28, wherein thedata processor is programmed to base its determination at least in partupon changes in at least a portion of the received data with time.

Aspect 30: The burner with monitoring of any of Aspects 27 to 29, theone or more sensors further including a first reactant pressure sensorpositioned in the primary first reactant passage for sensing a primaryoxidant pressure; wherein the data processor is programmed to identify apotential partial obstruction of the primary first reactant passagebased on a change to the primary first reactant pressure and the atleast one nozzle temperature.

Aspect 31: The burner with monitoring of any of Aspects 27 to 29,further comprising: a secondary first reactant passage spaced apart at afixed distance from the primary first reactant passage; and a stagingvalve for proportioning the first reactant between the primary andsecondary first reactant passages; the one or more sensors furtherincluding a staging valve position sensor for sensing a staging valveposition as indicative of the relative proportion of the first reactantbeing directed to the primary and secondary first reactant passages;wherein the data processor is further programmed to determine thepresence or absence of a partial obstruction of the primary firstreactant passage based on the staging valve position and the at leastone nozzle temperature.

Aspect 32: The burner with monitoring of any of Aspects 27 to 29,further comprising: a secondary first reactant passage spaced apart at afixed distance from the primary first reactant passage; and a stagingvalve for proportioning the first reactant between the primary andsecondary first reactant passages; the one or more sensors furtherincluding: a first reactant pressure sensor for sensing a first reactantpressure at one or more of upstream of the staging valve, downstream ofthe staging valve in the primary first reactant passage, and downstreamof the staging valve in the secondary first reactant passage; and astaging valve position sensor for sensing a staging valve position asindicative of the relative proportion of the first reactant beingdirected to the primary and secondary first passages; wherein the dataprocessor is further programmed to determine the presence or absence ofone or more of a partial obstruction of one of the primary firstreactant passage and the secondary first reactant passage and asub-optimal staging valve position based on the staging valve positionand the first reactant pressure at one or more of upstream of thestaging valve, downstream of the staging valve in the primary firstreactant passage, and downstream of the staging valve in the secondaryfirst reactant passage.

Aspect 33: The burner with monitoring of any of Aspects 31 and 32,further comprising: two pressure sensors, one positioned on either sideof a flow restriction device in at least one of the primary firstreactant passage, the primary second reactant passage, and the secondaryfirst reactant passage, for sensing a pressure upstream of the flowrestriction device, a pressure downstream of the flow restrictiondevice, and a differential pressure across the flow restriction deviceas indicative of flow rate; wherein the data processor is furtherprogrammed to determine the presence or absence of an abnormal burnercondition based on the differential pressure and one of the pressureupstream and downstream of the flow restriction device.

Aspect 34: The burner with monitoring of any of Aspects 27 to 33,further comprising: a burner block having a hot face adjacent to thefurnace; and a burner block temperature sensor for sensing a burnerblock temperature near the hot face; wherein the data processor isfurther programmed to determine the presence or absence of one or moreof burner block overheating and flame asymmetry based on the burnerblock temperature.

Aspect 35: The burner with monitoring of any of Aspects 27 to 34,further comprising: a position sensor for sensing a burner installationangle, the position sensor being configured to sense one or more of aburner pitch and a burner roll; wherein the data processor is furtherprogrammed to determine whether the burner is installed at a desiredorientation with respect to at least one feature of the furnace based onthe burner installation angle.

Aspect 36: The burner with monitoring of any of Aspects 27 to 35,further comprising: a data collector programmed to provide power toindividual sensors only when data is to be collected, based on one orboth of a combination of sensed data and a periodic schedule, and takinginto account the specific requirements of each of the individualsensors; a transmitter for wirelessly transmitting sensor data from thedata collector to the data processor; and a local power generationsystem for powering the data collector, the sensors, and thetransmitter.

Aspect 37: The burner with monitoring of any of Aspects 27 to 36,wherein the first reactant passage is annular and surrounds the secondreactant passage.

Aspect 38: The burner with monitoring of any of Aspects 27 to 37,wherein the first reactant is a fuel and the second reactant is anoxidant.

Aspect 39: The burner with monitoring of any of Aspects 27 to 37,wherein the first reactant is an oxidant and the second reactant is afuel.

Aspect 40: A method of determining an operating condition of an oxy-fuelburner including a first reactant passage terminating in a firstreactant nozzle, a primary second reactant passage terminating in asecond reactant nozzle, and a burner block having a face adjacent to thefurnace, the method comprising: sensing burner parameters from one ormore sensors selected from the group consisting of temperature sensors,pressure sensors, flow sensors, position sensors, angle sensors, contactsensors, accelerometers, optical sensors, and combinations thereof;comparing the sensed parameters with expected values for each saidburner parameter to determine the presence or absence of a deviation inthe burner parameter; and determining the presence of an abnormal burnercondition based on the presence of a deviation in one or more burnerparameters.

Aspect 41: The method of Aspect 40, further comprising: sensing at leastone of a first reactant nozzle temperature and a second reactant nozzletemperature; comparing the at least nozzle temperature to a thresholdtemperature; and determining a potential partial obstruction of one ofthe first and second reactant nozzles based on an increase or decreasein the at least one nozzle temperature.

Aspect 42: The method of Aspect 40 or 41, further comprising: sensing afirst reactant pressure; and determining a potential partial obstructionof the first reactant nozzle based on the first reactant pressure andthe at least one nozzle temperature.

Aspect 43: The method of Aspect 40 or 41, the burner further including asecondary first reactant passage spaced apart at a fixed distance fromthe primary first reactant passage and a staging valve for proportioningthe first reactant between the primary and secondary first reactantpassages, the method further comprising: sensing a staging valveposition indicating the proportion of the first reactant being directedto the primary and secondary first reactant passages; determining apotential partial obstruction of the primary first reactant passagebased on the staging valve position and the at least one nozzletemperature.

Aspect 44: The method of Aspect 40 or 41, the burner further including asecondary first reactant passage spaced apart at a fixed distance fromthe primary first reactant passage and a staging valve for proportioningthe first reactant between the primary and secondary first reactantpassages, the method further comprising: sensing a first reactantpressure from a location selected from upstream of the staging valve,downstream of the staging valve in the primary first reactant passage,and downstream of the staging valve in the secondary first reactantpassage; sensing a staging valve position indicating the proportion ofthe first reactant being directed to the primary and secondary firstreactant passages; determining one or more of a potential partialobstruction of one of the primary first reactant passage and thesecondary first reactant passage and a sub-optimal staging valveposition based on the staging valve position and the first reactantpressure at one or more of upstream of the staging valve, downstream ofthe staging valve in the primary first reactant passage, and downstreamof the staging valve in the secondary first reactant passage.

Aspect 45: The method of any of Aspects 40 to 44, further comprising:sensing pressures from two locations, one on either side of a flowrestriction device in at least one of the second reactant passage, theprimary first reactant passage, and the secondary first reactantpassage; determining a flow rate from the pressures at the twolocations; and determining the presence or absence of an abnormal burnercondition based on the flow rate and the pressure of at least one of thetwo locations.

Aspect 46: The method of any of Aspects 40 to 45, further comprising:sensing a burner installation angle, including at least one of a burnerpitch and a burner roll; and determining whether the burner is installedat a desired orientation with respect to at least one feature of thefurnace based on the burner installation angle.

Aspect 47: The method of any of Aspects 40 to 46, wherein the firstreactant passage is annular and surrounds the second reactant passage.

Aspect 48: The method of any of Aspects 40 to 47, wherein the firstreactant is a fuel and the second reactant is an oxidant.

Aspect 49: The method of any of Aspects 40 to 47, wherein the firstreactant is an oxidant and the second reactant is a fuel.

Other aspects of the invention are described below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is rear perspective view of an oxy-oil burner with monitoringfor insertion into a burner block.

FIG. 1B is a rear perspective view of an oxy-oil burner with monitoringas in FIG. 1A inserted in a burner block.

FIG. 2 is a front perspective view of an oxy-oil burner similar to theburner in FIG. 1A inserted in a burner block, but without monitoringcapabilities.

FIG. 3 is a rear perspective view of an oil lance for use in an oxy-oilburner with monitoring as in FIG. 1A.

FIG. 4 as a partial side view of an oil lance showing o-ring seals formaintaining and oil seal with the oil lance around a sensor access port.

FIG. 5 is a cross-sectional view of an oxy-oil burner with monitoringinserted in a burner block.

FIG. 6 is a graph showing exemplary pressure data comparing thedifference between the oil inlet pressure and the atomizing gas inletpressure for a fuel oil at different temperatures.

FIG. 7 is a graph showing exemplary pressure data comparing thedifference between the oil inlet pressure and the atomizing gas inletpressure for two fuel oil compositions and showing differences for oneof those fuel oil compositions when the nozzle tip is partially clogged,and when a temperature excursion occurred.

FIG. 8 is a schematic showing components of a communication system forcollecting, transmitting, and analyzing data collected from varioussensors on a burner, and for providing local power generation to a datacenter.

FIG. 9 is a rear perspective view of an oxy-gas burner with monitoringfor insertion into a burner block.

FIG. 10 is a partially cut away rear perspective view of an oxy-gasburner with monitoring as in FIG. 9.

FIG. 11 is a cross-sectional view of an oxy-gas burner with monitoringinserted in a burner block.

FIG. 12 is a rear perspective view of an oxy-gas burner with monitoringas in FIG. 9 inserted in a burner block.

FIG. 13 is a graph illustrating exemplary effects of a blockage in frontof a burner on oxygen pressure, natural gas pressure, and burner tiptemperature.

FIG. 14 is a graph illustrating exemplary effects of a blockage at aburner outlet on oxygen pressure, natural gas pressure, and burner tiptemperature.

FIG. 15 is a graph comparing oxygen pressure fluctuations in the sameburner with and without an obstruction placed at the burner outlet.

FIG. 16 is a graph illustrating the variations in oxygen pressure as afunction of firing rate and staging ratio.

FIG. 17A shows the pitch (angular deviation about an axis perpendicularto a longitudinal burner axis) and roll (angular deviation about an axiscoincident with the longitudinal burner axis), and FIG. 17B shows theeffect of pitch and roll on flame impingement at the burner face, wherepitch and roll are normalized to zero for operation with no flameimpingement.

FIGS. 18A and 18B are a top view and a front view, respectively, of aburner mounted in a burner block, showing thermocouples mounted in agrid in the burner block at front, middle, and rear locations axially,as well as at left, middle, and right locations laterally. FIG. 18Cshows measured block temperature at the lateral middle location for amisaligned burner that was fired first with 100% staging (relativelyflat temperature curves) and then 0% staging (upward sloping temperaturecurves).

FIG. 19 is a graph illustrating fuel oil lance tip temperature, oilpressure, and atomization pressure for an oxy-oil burner as in FIG. 1A,showing an lance temperature increasing steadily over time prior tocleaning of the oil nozzle, but oil pressure and atomization pressurenot showing the same clear trend.

FIG. 20 is a graph illustrating fuel oil lance tip temperature for anoxy-oil burner as in FIG. 1A at several different oxygen staging ratios.

DETAILED DESCRIPTION

Described herein is a burner system configured to be able to detect anabnormal burner condition, which may include, but is not limited to,partial obstruction of a flow passage, overheating of a portion of theburner, and/or improper installation orientation, and also todistinguish an abnormal burner condition from sensor failure.

FIGS. 1A, 1B, 2, and 5 depict an embodiment of a staged oxy-oil burner10 with integrated sensors, power supply, and communications equipment.FIGS. 9, 10, and 12 depict an embodiment of a staged oxy-gas burner 310with integrated sensors. Although particular embodiments of burners,either oxy-oil or oxy-gas, are described herein as an exemplaryembodiments of a burner with monitoring, the same or similarcommunications equipment and methods, along with similar or analogousintegrated sensors, customized to the configuration, design, andoperational mode of the particular burner, can be used on burners thatcombust gaseous fuel, liquid fuel, or solid fuel with an oxidant. Inparticular, with the exception of parameters that relate specifically tooil combustion, such as the oil and atomizing gas inlet pressures, allof the parameters and sensors described herein similarly apply to aburner for combusting any fuel, including gaseous fuel, solid fuel(e.g., petcoke) in a carrier gas, or liquid fuel.

Additionally, in a staged oxy-fuel burner, one or both of fuel andoxidant (e.g., oxygen) is staged such that a primary stream participatesin initial combustion while a secondary stream participates in delayedcombustion away from the burner. For example, for oxidant staging, theoxidant is proportioned between a primary oxidant passage and asecondary oxidant passage, with the secondary oxidant being supplied toat least one secondary oxidant nozzle spaced apart from the primaryoxidant nozzle(s) and fuel nozzle(s). Such staging may be accomplishedby a staging valve upstream of the primary and secondary oxidantpassages that proportions one incoming oxidant stream between the twopassages. Alternatively, the flow to each of the primary and secondaryoxidant passages may be independently controlled, manually orautomatically, by a separate control valve or by fixed flow restrictors.In other burners, fuel may be staged similarly, using either a stagingvalve or separate flow controls for primary and secondary streams.Further, in some burners, both fuel and oxidant may be staged.

The power supply is preferably a battery or local power generation forease of installation and to avoid possible safety issues with wiredpower. The sensors may include, in any combination, temperature sensors,pressure sensors, density sensors, flow sensors, position sensors, anglesensors, contact sensors, accelerometers, and optical sensors.

Examples of burners such as the burner 10 and the burner 310, butwithout sensors, are described in U.S. Pat. Nos. 5,575,637, 5,611,682,7,390,189, 8,172,566, and 8,512,033, which are incorporated herein byreference in their entirety.

The burner 10 has a discharge end 51 and an inlet end 19. Forconvenience of description, the discharge end 51 is sometimes referredto herein as the front or forward direction of the burner 10, while theinlet end 19 is sometimes referred to as the rear or rearward directionof the burner 10. When the burner 10 is mounted in a furnace, thedischarge end 51 faces the interior of the furnace.

The burner 10 includes a burner block 12, a burner body 14 positionedrearward from burner block 12 with respect to the furnace, and aninstrument enclosure 16 positioned rearward with respect to the burnerbody 14. The burner body 14 includes a mounting plate 53 that is securedto the burner block 12. The burner block 12 has a front face 18 that,when mounted, faces into the furnace.

The burner block 12 includes a primary oxidant passage 30. In thedepicted embodiment, the primary oxidant passage 30 has an elongatedcross-sectional shape with a major axis (defining a width) longer than aminor axis (defining a height). In particular, the depicted primaryoxidant passage 30 has the shape of a rectangle with semi-circular ends,and a width-to-height ratio from about 5 to about 30. However, in otherembodiments, the primary oxidant passage 30 may have a circular, oval,ovalized rectangular, rectangular, or other shape.

An oil lance 20 is positioned within the primary oxidant passage 30 andhas an oil nozzle 22 at its discharge end. In the depicted embodiment,the oil nozzle is an atomizing nozzle 22. The atomizing nozzle 22 issubstantially surrounded by the primary oxidant passage 30 so thatatomized fuel oil discharged from the nozzle 22 will mix intimately withthe primary oxidant stream upon discharge. Preferably, the oil lance 20and the nozzle 22 are separately manufactured parts that are joinedtogether, for example by welding, to form a unitary lance with nozzle.In the depicted embodiment, the oil lance 20 substantially centrallypositioned within the primary oxidant passage 30, although it isunderstood that the oil lance 20 may be located in a non-centrallocation provided the nozzle 22 is adapted to distribute the atomizedoil to be adequately mixed with the primary oxidant stream forcombustion. Alternatively, for an oxy-gas burner, a gaseous fuel passagecan be positioned within the primary oxidant passage 30 in place of theoil lance 20.

The burner block 12 further includes a secondary oxidant passage 40spaced apart by a fixed distance from the primary oxidant passage 30. Inthe depicted embodiment, the secondary oxidant passage 40 has anelongated cross-sectional shape with a major axis (defining a width)longer than a minor axis (defining a height), similar to the primaryoxidant passage 30. In particular, the depicted secondary oxidantpassage 40 has the shape of a rectangle with semi-circular ends, and awidth-to-height ratio from about 5 to about 30, which may be the same asor different from the width-to-height ratio of the primary oxidantpassage 30. The major axis of the secondary oxidant passage 40 issubstantially parallel to the major axis of the primary oxidant passage30. However, in other embodiments, the second oxidant passage 40 mayhave a circular, oval, ovalized rectangular, rectangular, or othershape, and preferably but not necessarily approximately the same shapeas the primary oxidant passage 30.

The primary oxidant passage 30 is fed oxidant from a primary oxidantconduit 32 positioned in the burner body 14 and extending into a rearportion of the burner block 12. Oxidant is fed through a pair of oxidantinlets 38 into an oxidant plenum 36 that in turn feeds the primaryoxidant conduit 32. A diffuser 34 may be positioned between the oxidantinlets 38 and the oxidant plenum 36 to aid in straightening out theprimary oxidant flow prior to entering the primary oxidant conduit 32.

The secondary oxidant passage 40 is fed oxidant from a secondary oxidantconduit 42 positioned in the burner body 14 and extending into a rearportion of the burner block 12. A staging valve 48 in the burner body 14redirects a portion of the oxidant supplied by the oxidant inlets 38into the secondary oxidant conduit 42. The term “staging ratio” is usedto describe the proportion of oxidant that is redirected to thesecondary oxidant conduit 42, and thus away from the primary oxidantconduit 32. For example, at a staging ratio of 30%, 70% of the oxidantis directed to the primary oxidant conduit 32 (and thus to the primaryoxidant passage 30) as a primary oxidant stream and 30% of the oxidantis directed to the secondary oxidant conduit 42 (and thus to thesecondary oxidant passage 40) as a secondary oxidant stream.

The oxidant gas fed to the oxidant inlets 38 may be any oxidant gassuitable for combustion, including air, oxygen-enriched air, andindustrial grade oxygen. The oxidant preferably has a molecular oxygen(O2) content of at least about 23 mol %, at least about 30 mol %, atleast about 70 mol %, or at least about 98 mol %.

The oil lance 20 extends rearward through the burner body 14 and throughthe instrument enclosure 16. Fuel oil is supplied to the oil lance 20through an oil inlet 26. Due to the viscosity of fuel oil, it istypically necessary to also supply an atomizing gas to the oil lance 20through an atomizing gas inlet 28. The atomizing gas may be any gascapable of atomizing the fuel oil as it exits the nozzle 22, includingair, oxygen-enriched air, or industrial grade oxygen.

Various temperature sensors may be used for monitoring the temperatureof burner components and for help in determining fuel inlet conditions.In the depicted embodiment of FIGS. 1A, 1B, 2, and 5, a temperaturesensor 102 such as a thermocouple is embedded in the atomizing nozzle 22in the oil lance 20 for measuring the temperature at the discharge endof the oil lance 20. The temperature sensor 102 may be a thermocouple orany other suitable sensor. The sensor 102 is fitted into a blind hole(not shown) in a rear side of the nozzle 22. Because the sensor 102 mustbe removable for maintenance and replacement, it is not welded in place.Leads (not shown) connected to the temperature sensor 102 are routedback along the oil lance 20 to the instrument enclosure 16. To protectthe leads 104 from abrasion, overheating, and other harsh conditions ofthe furnace environment, it is desirable to encase the leads. However,it is difficult from a manufacturing perspective to form a smalldiameter hole for a substantial portion of the length of the oil lance20. Therefore, the leads are preferably recessed in a channel 106 alongthe length of the lance, and a sheath (not shown) is positioned over thechannel 106 to protect the leads. In one embodiment, the sheath mateswith an outer wall of the lance 20 to seal the leads and temperaturesensor 102 from the furnace environment, to provide mechanicalprotection to the leads and temperature sensor 102, and to limit theflow disturbances of the primary oxidant stream flowing in the primaryoxidant passage 30 and around the oil lance 20.

Temperature sensors may be placed on other components of the burner 10to monitor operational parameters such as burner integrity, flamestability, flame position. For example, one or more temperature sensors110 may be mounted in the burner block 12 near the front face 18 or nearthe flow passages. The temperature sensors 110 are preferably set backslightly from the front face 18 to protect them from the furnaceenvironment. The temperature sensors 110 may be centered with respect tothe primary oxidant passage 30, or offset from the minor axiscenterline. and may be used to determine whether the flame is impingingon the burner block 12 or whether the flame is centered about the oillance 20 or the primary oxidant passage 30. Temperature sensors may evenbe positioned in other locations of the furnace proximate to the burnerfor monitoring combustion conditions. Optical sensors may also, oralternatively, be used to monitor the light intensity from the block,with increased emissions from the block indicating potential flameimpingement.

An oil feed temperature sensor 112 is positioned in the oil stream nearthe oil inlet 26 to monitor the temperature of the oil being supplied tothe burner 10. It is important to ensure that the viscosity of the oilstream will enable proper oil atomization, and the viscosity is afunction of temperature as well as oil composition. Therefore, for anyparticular oil composition, an optimum temperature range can bedetermined for atomization.

The oil feed temperature sensor 112 must be able to measure the oilinlet temperature, but is preferably also positioned so as to permitlance cleaning without removing the temperature sensor 112. In thedepicted embodiment of a rear portion of the oil lance 20 in FIG. 4, asealing mechanism 61 is provided at the rear portion of the lance 20.The sealing mechanism 61 includes a body 23 through which the bore 21extends in a longitudinal direction, and a sleeve 64 surrounding thebody 23. The sealing mechanism 61 enables the temperature sensor 112 tobe near the flowing oil stream in the lance 20 but also out of the wayof the bore 21 of the lance 20, so that the bore 21 can be cleaned andso that the body 23 can be removed from the sleeve 64 without removingthe temperature sensor 112. The body 23 includes a sensor well 68surrounded to the front and rear by two pairs of o-rings 70 seated ino-ring grooves 72, which seal against an inner surface 74 of the sleeve64. An access opening 69, or multiple such openings, enables oil flowingthrough the bore 21 to enter the sensor well 68.

A sensor port 67 is located in the sleeve 64, and the temperature sensor112 is secured (e.g., by threads or other mechanism) into the sensorport 67 so as to have its sensing tip flush with or slightly recessedfrom the inner surface 74 of the sleeve 64. Experiments have shown thata temperature sensor 112 mounted as shown and described is appropriatelysensitive in responding to changes in oil inlet temperature.Consequently, the temperature sensor 112 is able to measure the oiltemperature in the bore 21, or at least a temperature that hasexperimentally shown to be accurately representative of the oiltemperature, while still permitting the body 23 to be removed from thesleeve 64 for cleaning without having to disturb the temperature sensor112.

Because the sensor well 68 extends around the entire circumference ofthe body 23, the body 23 may include multiple sensor ports 67 to enablemounting of multiple sensors. Also, multiple access openings 69 may bepresent to provide better uniformity of the oil in the sensor well 68.This arrangement allows the oil stream to contact the temperature sensor112 while maintaining a seal with the sleeve 64 to prevent any oilleakage. Specifically, by mounting the temperature sensor 112 nearlyflush with the bore, the temperature sensor 112 is in contact with oilthat is indicative of current oil temperatures. Also, by being flush ornearly flush, the temperature sensor 112 will not block physicalcomponents that are inserted into the bore 21 of the oil lance 20 forcleaning and to allow the body 23 to be removed from the oil lance 20for cleaning. In one embodiment, the temperature sensor 112 may befitted with a male NPT fitting to mate with a female NPT thread in thesensor port 67.

In the depicted embodiment, pressure sensors are also installed in theburner 10. A pressure sensor 114 is positioned in the oil stream nearthe oil inlet 26. The pressure sensor 114 may be mounted in the samesealing mechanism 61 as the temperature sensor 112, with the pressuresensor 114 being located in a different sensor port (not shown).Alternatively, the pressure sensor 114 may be mounted in a separatesealing mechanism having essentially the same construction as thesealing mechanism 61.

In the embodiment of FIG. 5, a pressure sensor 116 is mounted in theatomizing gas stream near the atomizing gas inlet 28, and a pressuresensor 128 is mounted in the oxidant stream either near one of theoxidant inlets 38 or in the oxygen plenum 36 upstream of the stagingvalve 48. If desired, separate oxidant pressure sensors may be mountedin each of the primary oxidant conduit 32 and the secondary oxidantconduit 42 to detect the pressure of oxidant being supplied to each ofthe oxidant passages 30 and 40, respectively, in the burner block 12.The pressure sensors may be located inside or outside of the instrumentenclosure 16, and are wired by cable for both power supply and signaltransmission.

As shown, the instrument enclosure 16 includes a battery port 81 and anantenna 62 for wireless communication of data.

Note that similar configurations to the foregoing could be used to mountother sensors to monitor any of the feed streams.

In the depicted embodiment of FIGS. 1A to 5, the burner 10 also has aposition sensor or rotation sensor 124 on the staging valve 48 to detectthe percent staging. The rotation sensor 124 could be a Hall effect typesensor, accelerometer type sensor, a potentiometer, optical sensor, orany other sensor that can indicate rotational position. Additionalposition and angle sensors may be used to determine the position and/orangle of the burner body 14 relative to the furnace or the burner block12, the position and/or angle of the lance 20 relative to the burnerbody 14 or the burner block 12, the insertion depth of the lance 20, andany other angles or positions that may be relevant to the operation ofthe burner 10.

For example, position sensors on the oil lance 20 can be used to detectand verify correct insertion depth and to log the information fortracking performance. Angle sensors on the burner 10 can be used toensure that the burner is installed properly. This could be for ensuringthat the burner is seated properly against the mounting plate forseating positive seal. In addition it is sometime desirable to installthe burner at a given angle with respect to horizontal. Other sensorssuch as contact sensors between the burner and mounting plate could beused to ensure proper mounting of the burner to the mounting plate. Byusing one or more such sensors (preferably at least two) the burner cando a check on its installation to ensure that it is not ajar and isindeed in contact with both sensors (for example, a top sensor and abottom sensor, or a left sensor and right sensor, or all fourpositions).

Additional connection ports may be located on the oil lance 20, theburner body 14, and/or the burner block 12 to enable additional externalsensors or other signals to be connected to the data collector fortransmission to a data indicator.

In one embodiment of the system of FIGS. 1A to 5 (or similarly thesystem of FIGS. 9 to 12), one or more burner components have a uniqueidentifier. Specifically for a oil burner 10, the body 14 and each oillance 20 may each have a unique identifier. This is useful since oillances can be separated from the burner body and may be switched todifferent burner bodies. By incorporating a unique identifier on theburner body and lance, the communications equipment in the instrumentbox, which travels with the lance, can identify which burner body it isconnected to for historical data archiving, trend analysis, and otherreasons. This identifier could be RFID, a type of wireless transmitter,bar code, a one-wire silicon serial number, a unique resistor, a codedidentifier, or any other identifying means.

Measuring the oil pressure can provide information about the flowresistance of the oil lance (e.g., decreased flow area due to coking orsome other blockage will cause a pressure rise), the flowrate of theoil, and the viscosity of the oil (which is a function of temperatureand composition). The oil pressure information is likely to be moreuseful when combined with other information (e.g., the oil temperature,the oil flowrate, the burner tip temperature, and data trending) indetecting maintenance needs of the oil lance.

Measuring the atomizing oxidant pressure also provides information aboutthe oil flowrate and resistance and is therefore related to the oilpressure, but it is typically not the same and provides another elementof information. Both of these instruments are located within theinstrument box on the oil lance.

The oxygen pressure measurement provides information about the oxygenflowrate, flow resistance (i.e. blockage that may occur), and stagingvalve position.

The instrument enclosure 16, which is shown in partial cutaway in FIGS.1A and 1B, is sealed and insulated to protect instrumentation containedtherein from the dust and heat of a furnace environment. The instrumentenclosure is positioned toward the rear 19 of the burner 10 to reducethe radiant heat energy received from the furnace. The instrumentenclosure 16 includes at least a data collector 60, a power supply, anda transmitter 62 for sending data from the data collector to a datareceiver 200 (which may collect and display data from multiple burners)located either locally or remotely. In one embodiment, the transmitter62 is incorporated into the data collector 60. A data processorprocesses the data from all of the sensors and may be incorporated intothe data collector 60 (e.g., data processor 66), located in theinstrument enclosure 316 separately from the data collector 60 (e.g.,data processor 166), or located at a remote location integral with orseparate from the data receiver 200 (e.g., data processor 266).

In the embodiment depicted in FIGS. 9, 10, 11, and 12, the burner 310has a discharge end 351 and an inlet end 319. For convenience ofdescription, the discharge end 351 is sometimes referred to herein asthe front or forward direction of the burner 310, while the inlet end319 is sometimes referred to as the rear or rearward direction of theburner 310. When the burner 310 is mounted in a furnace, the dischargeend 351 faces the interior of the furnace.

The burner 310 includes a burner block 312, a burner body 314 positionedrearward from burner block 312 with respect to the furnace, and aninstrument enclosure 316 positioned rearward with respect to the burnerbody 314. The burner body 314 includes a mounting plate 353 that issecured to the burner block 312. The burner block 312 has a front face318 that, when mounted, faces into the furnace.

The burner 310 includes a primary oxidant passage 330. In the depictedembodiment, the primary oxidant passage 330 has an elongatedcross-sectional shape with a major axis (defining a width) longer than aminor axis (defining a height). In particular, the depicted primaryoxidant passage 330 has the shape of a rectangle with semi-circularends, and a width-to-height ratio from about 5 to about 30. However, inother embodiments, the primary oxidant passage 330 may have a circular,oval, ovalized rectangular, rectangular, or other shape. The primaryoxidant passage has a primary oxidant nozzle 333 at its discharge end.

A fuel passage 320 is positioned within the primary oxidant passage 330and has a fuel nozzle 322 at its discharge end. The fuel nozzle 322 issubstantially surrounded by the primary oxidant nozzle 333 so that fueldischarged from the fuel nozzle 322 will mix intimately with the primaryoxidant stream from the oxidant nozzle 333 upon discharge. In thedepicted embodiment, the fuel passage 320 has an elongatedcross-sectional shape with a major axis (defining a width) longer than aminor axis (defining a height). In particular, the depicted fuel passage320 has the shape of a rectangle with semi-circular ends, and awidth-to-height ratio from about 5 to about 30.However, in otherembodiments, the fuel passage 320 may have a circular, oval, ovalizedrectangular, rectangular, or other shape. In the depicted embodiment,the fuel passage 320 is substantially centrally positioned within theprimary oxidant passage 330, although it is understood that the fuelpassage 320 may be located in a non-central location provided the fuelnozzle 322 is adapted to distribute the fuel to be adequately mixed withthe primary oxidant stream for combustion. Preferably, but notnecessarily, the fuel passage 320 approximately the same shape as theprimary oxidant passage 330.

The burner 310 further includes a secondary oxidant passage 340 spacedapart by a fixed distance from the primary oxidant passage 330. In thedepicted embodiment, the secondary oxidant passage 340 has an elongatedcross-sectional shape with a major axis (defining a width) longer than aminor axis (defining a height), similar to the primary oxidant passage330. In particular, the depicted secondar oxidant passage 340 has theshape of a rectangle with semi-circular ends, and a width-to-heightratio from about 5 to about 30, which may be the same as or differentfrom the width-to-height ratio of the primary oxidant passage 330. Themajor axis of the secondary oxidant passage 340 is substantiallyparallel to the major axis of the primary oxidant passage 330. However,in other embodiments, the second oxidant passage 340 may have acircular, oval, ovalized rectangular, rectangular, or other shape, andpreferably but not necessarily approximately the same shape as theprimary oxidant passage 330.

The primary oxidant passage 330 is fed oxidant from a primary oxidantconduit 332 positioned in the burner body 314 and extending into a rearportion of the burner block 312. Oxidant is fed through a pair ofoxidant inlets 338 into an oxidant plenum 335 that in turn feeds theprimary oxidant conduit 332. A diffuser 334 may be positioned betweenthe oxidant inlets 338 and the oxidant plenum 335 to aid instraightening out the primary oxidant flow prior to entering the primaryoxidant conduit 332.

The secondary oxidant passage 340 is fed oxidant from a secondaryoxidant conduit 342 positioned in the burner body 314 and extending intoa rear portion of the burner block 312. A staging valve 348 in theburner body 314 redirects a portion of the oxidant supplied by theoxidant inlets 338 into the secondary oxidant conduit 342. The term“staging ratio” is used to describe the proportion of oxidant that isredirected to the secondary oxidant conduit 342, and thus away from theprimary oxidant conduit 332. For example, at a staging ratio of 30%, 70%of the oxidant is directed to the primary oxidant conduit 332 (and thusto the primary oxidant passage 330) as a primary oxidant stream and 30%of the oxidant is directed to the secondary oxidant conduit 342 (andthus to the secondary oxidant passage 340) as a secondary oxidantstream.

The oxidant gas fed to the oxidant inlets 338 may be any oxidant gassuitable for combustion, including air, oxygen-enriched air, andindustrial grade oxygen. The oxidant preferably has a molecular oxygen(O2) content of at least about 23 mol %, at least about 30 mol%, atleast about 70 mol %, or at least about 98 mol %.

The fuel passage 320 extends rearward through the burner body 314 andthrough the instrument enclosure 316. Fuel is supplied to the fuelpassage 320 through a fuel inlet 326.

Although the embodiment described herein stages oxidant flow andincludes a primary oxidant passage 330, a secondary oxidant passage 340,and a fuel passage 320, an analogous burner have an analogous physicalstructure can be used which stages fuel flow and includes a primary fuelpassage, a secondary fuel passage, and an oxidant passage. Moregenerically, a burner can be described as combusting a first reactant(which is one of a fuel and an oxidant) and a second reactant (which isthe other of a fuel and an oxidant), the burner including a primaryfirst reactant passage, a secondary first reactant passage, and a secondreactant passage.

Various sensors may be used for monitoring parameters of burnercomponents. In the depicted embodiment of FIGS. 9, 10, 11, and 12,various sensors are shown for monitoring and controlling burneroperation.

Temperature sensors may be placed on or in the burner 310 itself or oncomponents of the burner 310, or in other portions of the furnace. Forexample, temperature sensors on the burner 310 can monitor operationalparameters such as burner integrity, flame stability, flame position,while temperature sensors in the furnace can measure the temperature ofthe charge before, during, and after firing of the burner to provideinformation about the rate of heat transfer and distribution of heatfrom the burner. The sensors may be of any type, including withoutlimitation thermocouples and optical (e.g., infrared) sensors.

In the depicted embodiment of FIG. 11, a temperature sensor 372 ismounted in the primary oxidant passage 330 at or near the oxidant nozzle333 for monitoring the temperature of the primary oxidant passage 330 orthe oxidant nozzle 333. Alternatively, or in combination with theoxidant sensor, a temperature sensor 372 could mounted in the fuelpassage 320 at or near the fuel nozzle 322 for monitoring thetemperature of the fuel passage 320 or the fuel nozzle 322. In otherembodiments, temperature sensors may be mounted in the burner block 312near the front face 318 or near the flow passages. The connection pointsto two temperature sensors 372 are shown in FIG. 10. When mounted in theburner face 318, the temperature sensors 372 are preferably set backslightly from the front face 318 to protect them from the furnaceenvironment. The temperature sensors 372 may be centered with respect tothe primary oxidant passage 330 or the fuel passage 320, or offset fromthe minor axis centerline. and may be used to determine whether theflame is impinging on the burner block 312 or whether the flame iscentered about the fuel passage 320 or the primary oxidant passage 330.Temperature sensors may even be positioned in other locations of thefurnace proximate to the burner for monitoring combustion conditions.Optical sensors may also, or alternatively, be used to monitor the lightintensity from the block, with increased emissions from the blockindicating potential flame impingement.

In the depicted embodiment of FIGS. 11 and 12, pressure sensors areinstalled in the burner 310. A pressure sensor 380 is positioned in thefuel passage 320 for measuring the fuel pressure upstream of the fuelnozzle 322. Another pressure sensor 376 is mounted in the oxidant streameither near one of the oxidant inlets 338, or in the oxygen plenum 335upstream of the staging valve 348 to measure the oxidant pressureupstream of the staging valve, or upstream of the diffuser 334 tomeasure oxidant inlet pressure upstream of the diffuser 334. If desired,separate oxidant pressure sensors may be mounted in each of the primaryoxidant conduit 332 (pressure sensor 378) and/or in the secondaryoxidant conduit 342 (pressure sensor 379) to measure the pressure ofoxidant being supplied to either or both of the oxidant passages 330 and340 in the burner block 312. The pressure sensors 378 and 379 arelocated downstream of the diffuser 334, and one or both may be used incombination with the pressure sensor 376 to determine flow rate based onpressure drop across the diffuser 334. The pressure sensors may belocated inside or outside of the instrument enclosure 316, and are wiredby cable for both power supply and signal transmission. The burner 310may further include a density sensor 388, for example as described in USPatent Pub. No. 2014/0000342, that is mounted in the fuel passage 320(as shown) and/or in the primary oxidant passage 330 (not shown).

As shown, the instrument enclosure 316 includes a battery port 382 forhousing a local power supply (e.g., a battery) to provide power to thecomponents in the instrument enclosure 116, as well as to the varioussensors. The instrument enclosure 316 further includes an antenna 62 forwireless communication of data. The enclosure 316 also includes aposition and angle sensing apparatus 370 measuring angles as shown inFIG. 17A and discussed in further detail below. Such position and anglesensors may be used to determine the position and/or angle of the burnerbody 314 relative to the furnace or the burner block 312 and any otherangles or positions that may be relevant to the operation of the burner310. Additionally, the burner 310 also has a position sensor or rotationsensor 384 on the staging valve 348 to detect the percent staging. Therotation sensor 384 could be a Hall effect type sensor, accelerometertype sensor, a potentiometer, optical sensor, or any other sensor thatcan indicate rotational position. The instrument enclosure 316 may alsoinclude an LED 386 or other light source for illuminating the internalsof the burner 310, and/or for indicating burner operating status.

The oxygen pressure measurements provides information about the oxygenflowrate, flow resistance (i.e., potential blockage that may occur), andstaging valve position. The fuel pressure measurement providesinformation about fuel flowrate and flow resistance (i.e., potentialblockage that may occur). Interpretation and use of data relating tothese sensors is discussed in further detail below.

In the depicted embodiment of FIGS. 9 to 12, the burner 310 also has aposition sensor or rotation sensor 384 on the staging valve 348 todetect the percent staging. The rotation sensor 384 could be a Halleffect type sensor, accelerometer type sensor, a potentiometer, opticalsensor, or any other sensor that can indicate rotational position.Additional position and angle sensors may be used to determine theposition and/or angle of the burner body 314 relative to the furnace orthe burner block 312, and any other angles or positions that may berelevant to the operation of the burner 310.

The instrument enclosure 316 is similar to the instrument enclosure 16discussed above, and is sealed and insulated to protect instrumentationcontained therein from the dust and heat of a furnace environment. Theinstrument enclosure is positioned toward the rear 319 of the burner 310to reduce the radiant heat energy received from the furnace. Theinstrument enclosure 316 includes at least a data collector 60, a powersupply, and a transmitter 62 for sending data from the data collector toa data receiver 200 (which may collect and display data from multipleburners) located either locally or remotely. A data processor processesthe data from all of the sensors and may be incorporated into the datacollector 60 (e.g., data processor 66), located in the instrumentenclosure 316 separately from the data collector 60 (e.g., dataprocessor 166), or located at a remote location integral with orseparate from the data receiver 200 (e.g., data processor 266).

The power supply is used to power the pressure sensors, the datacollector, and the transmitter, and any other sensors and equipmentrequiring power. Preferably, the power supply is powered by a localbattery that may or may not be charged via local energy harvesting orpower generation to avoid having to wire outside power to the instrumentenclosure 316. For example, local power generation may include usingtemperature gradients, mass flow, light, induction, or other means togenerate sufficient power to support the sensors and other associatedequipment in the instrument enclosure 316.

FIG. 8 is a schematic of an exemplary system for handling the burnerdata, it being understood that various alternative combinations ofhardware, firmware, and software could be configured and assembled toaccomplish the same functions. One or more burners 10, 310 may bemounted in the furnace 70, each burner 10, 310 having an instrumentenclosure 16, 316, respectively, as described above. In the schematic ofFIG. 8, multiple burners 10, 310 are mounted in the furnace 70. Eachinstrument enclosure 16, 316 contains a data collector 60 for collectingand aggregating the data generated by each of the sensors on the burner10, and a wireless transmitter 62 for transmitting the data from thedata collector 60, as well as other components such as a power supply(not shown). The data collector 60 is programmable via one or more ofhardware, firmware, and software, independently or in combination, toperform application-specific functions. The data collector 60 mayinclude an integral data processor 66, or a separate data processor 166may be located in the instrument enclosure 16, 316.

In an exemplary embodiment, the data collector 60 at each burner 10, 310aggregates data for that burner 10, 310 using a highly configurableWireless Intelligent sensor Node (WIN). The data collector 60 powers thevarious sensors associated with the burner 10, and is programmed toconvert a battery voltage of between 3.2V and 6V, for example to thecorrect voltage required by each sensor (e.g., 12V). The battery voltagecan be supplied by locally mounted batteries that are replaceable orthat are charged by local power generation. In one embodiment, thesensors transmit analog output signals that are read via ananalog-to-digital converter with a programmable gain amplifier to takeinto account the output range of each sensor. In another embodiment, thesensors transmit digital output signals that are scaled, or that may bescaled, based on the output range of each sensor.

The data collector 60 is also capable of reading digital sensors orindicators such as a serial number. An internal temperature sensorallows monitoring of the ambient temperature and thus cold junctioncompensation of thermocouples. An internal accelerometer allows theattitude of the node (and therefore what it is attached to) to bemeasured. Advanced power management is used to maximize battery life. Inparticular, the data collector 60 is programmed to power the sensorswhen measurements are to be taken, either based on a combination ofsensed conditions or on a regular schedule.

The sensor measurements are consolidated, taking into account the gainof the amplifier taken, cold junction compensation, and any otherrelevant factors, and transmitted to a data receiving/processing center200, preferably via a wireless link. In an exemplary embodiment, thewireless link uses the 2.4 GHz ISM band and the 802.15.4 standard as itsphysical layer and Medium Access Control (MAC). However, any otherwireless link now known or later developed that is suitable for theoperating environment could be used. The protocol uses a star networktopology. Alternative frequencies and protocols are possible, includingwithout limitation mesh network topologies. The 2.4 GHz band was chosensince it is a worldwide ISM band while most other ISM bands are countryspecific. The wireless link to the node is bidirectional to allowconfiguration of the node over the air. The data may be encrypted priorto transmission for security purposes. The data may be transmitteddirectly from the data collector 60 to the data center 200, orindirectly via one or more Wi-Fi or other repeaters depending on thedistance and signal path between the burner 10, 310 and the data center200.

The data center 200 is configured to receive data from the individualburners 10, 310, and may also be configured to transmit data to acloud-based server which can then serve data, provide alerts, andperform any other computational function via the Internet or othernetwork. The data center 200 may be a single piece of hardware ormultiple cooperating pieces of hardware configured and programmed toperform all of the desired functions described herein. The data center200 may also include a data display (not shown) either at the burner ornearby using an accompanying piece of hardware that has a displaymodule. The data center 200 may include, or may be connected to, a dataprocessor 266.

Electrical power may be supplied to the data collector 60 by a localpower generation system. FIG. 8 shows an exemplary local powergeneration system 208 to provide electrical power to the data center200. Note that a similar arrangement may also be employed to providelocally generated electrical power to the data collector 60. In thedepicted embodiment, the local power generation system 208 includes arechargeable battery 206 or super capacitor, and an energy harvester204. The rechargeable battery 206 may include, for example, one or morelithium ion batteries or the like. Charging and discharging of thebattery 206 is controlled by a battery supervisor 202, which ispositioned as a hub between the data center 200, the battery 206, andthe energy harvester 204. The battery supervisor 202 can be configuredto perform various functions, including but not limited to one or moreof the following, alone or in combination: conditioning power flowing toand from the battery 206 and the energy harvester 204, maximum powerpoint tracking to maximize harvested energy efficiency from the energyharvester 204, and permitting the data collector 60 to turn on only whenthere is sufficient energy available in the battery 206. Local powergeneration systems 208 as described herein may be used to respectivelypower one or more data centers 200, and/or individual data collectors 60located at each burner 10, 310 and/or one local power generation systemmay power one or more nearby data collectors 60. These local powergeneration systems can operate to store power during periods of lowusage and release power during periods of high usage, thereby minimizingthe required capacity of the energy harvester. In addition, similarlocal power generation systems 208 can be used to power one or more datacenters 200.

Advanced power management helps ensure long-term operation of the systemon limited battery or locally generated power supply. Power is suppliedto a Wireless Intelligent sensor Node (WIN) that is highly configurableto provide the correct required voltage to each of the differentsensors. Moreover, the WIN intelligently turns off power to individualsensors when they are not in use, collects data from the sensors when inuse, and transmits the data at configurable time intervals. An indicatorlight shows the status of the system and also provides alerts. Bypowering the sensors only when they are used (e.g., on a predeterminedtime rotation to obtain periodic measurements), this conserves powerfrom the power supply. However, it has been determined that somesensors, including but not limited to pressure sensors, may not givereliable data immediately after being powered up and do not respond wellto being powered for only brief amounts of time. Therefore, the systemrequires both careful selection of sensors and specific configuration ofthe WIN to match the power up and power down cycles with the operatingrequirements of each sensor.

The data collector 60 receives signals from all the sensors, and thetransmitter 62 sends the collected signal data to a data indicator wherea user can view the status of the various parameters being measured. Thedata collector 60 may also include a data processor 66 or 166, or maysend the collected signal data via the transmitter to a separate dataprocessor 266.

Measuring the various temperatures, pressures, and positions of theburner and its components and feed streams and inputs from the otherassociated equipment including flow control skids, separately and incombination, can provide valuable information that enables an operatorto perform preventive maintenance only when needed and to avoid costlyunexpected failures or shutdowns. In one embodiment, position sensorscan include GPS or other local triangulation position indicators todetermine the installation location of a burner and/or its components.Alternatively, and any presently known or newly developed method may beused to determine location.

In one example of an oxy-oil burner, high oil tip temperature along withhigher than expected oil pressure and atomizing gas pressure mayindicate that the oil nozzle is clogged or is starting to clog. Thisalerts an operator that maintenance should be performed soon so that thetip does not burn up in hot furnace. As shown in FIG. 19, the tiptemperature may indicate a need for nozzle cleaning better thanpressures alone. In the illustrated example, oil pressure and atomizingair pressure are monitored in addition to the tip temperature before andafter nozzle cleaning. While the tip temperature increases fairlyuniformly, the pressure changes are not as clear with time, therebymaking it more difficult to determine the need for oil nozzle cleaningbased on pressures alone. After cleaning of the oil nozzle the tiptemperature drops dramatically and the pressures change as well. Howeverrelying on tip temperature alone may not be reliable since there areother factors that affect tip temperature in addition to lance nozzlelifetime. For example, FIG. 20 shows the results of monitoring lance tiptemperature while changing the oxygen staging level for an oxy-oilburner. Here the direct correlation between the staging level and thetip temperature is apparent. Therefore multiple pieces of informationare preferred for a reliable interpretation of the data. By combiningthe staging level, lance history, pressures, and temperatures, it ispossible accurately determine when the oil nozzle needs to be cleaned.

The lance or fuel nozzle tip temperature may also be an indicator ofcombustion stability or the proximity of the flame root to the burner.However, as noted above, a knowledge of other burner conditions isimportant to accurately interpret the possible cause of a change in fuelnozzle temperature.

The difference between the oil inlet pressure and atomizing gas inletpressure can provide an estimate of the expected firing rate, since fora given firing rate, there would be an expected pressure differencebetween the oil and atomizing gas. However, this estimate of firing ratemay be affected by clogging as seen in FIG. 19. Alternatively, or incombination with measuring the difference between the oil and atomizinggas pressures, the oxygen inlet pressure and staging valve position canbe used to calculate the firing rate based on an assumed stoichiometry,and this measurement is not typically affected by oil nozzle clogging.So for any firing rate, if the pressure difference between the oil andatomizing gas is more than expected (taking into account the oilviscosity based on the measured oil temperature and known or assumedcomposition), this is an indication that some clogging is occurring andmaintenance is needed.

FIG. 6 compares the pressure difference between the oil inlet and theatomizing gas inlet pressures as a function of firing rate for a knowncomposition of fuel oil at three different oil temperatures. In allcases, the atomizing nozzle was clean and unobstructed. As can be seenfrom the data, the pressure difference is greater at all firing ratesfor the lower temperature oil, with the pressure difference becominglarger in both absolute and relative terms at the higher firing rates.Testing has shown that this pressure difference is a much betterindicator of the health of the atomizing nozzle than the oil inletpressure alone.

FIG. 7, on the same axes as FIG. 6, compares three situations at 175°F.: the triangular data points represent a first fuel and are the samedata as the triangular data points on FIG. 6; the circular data pointsrepresent a second fuel having a more viscous composition at the sametemperature conditions with a clean atomizing nozzle; and the diamonddata points represent the first fuel but flowing through a partiallyobstructed atomizing nozzle. It can clearly be seen that the secondfuel, due to its higher viscosity, exhibits a significantly higherpressure difference (between the oil inlet pressure and the atomizinggas pressure) than the lower viscosity first fuel, and that the pressuredifference rises significantly when the atomizing nozzle is partiallyobstructed or clogged.

Additionally, the diamond shaped data point in the top right of thegraph occurred during a temperature excursion of the atomizing nozzlewhen the temperature had unexpectedly changed, thereby showing thatmultivariable monitoring that takes into account secondary effects canalso be useful as an internal check on the proper operation of all ofthe sensors and the system.

Further, using any estimate of firing rate (however determined) providesan expected oil pressure. If the oil pressure is higher than theexpected oil pressure then either some clogging is occurring or the oilviscosity is lower than expected. A higher than expected oil pressurecombined with the oil inlet temperature would help determine whether theoil viscosity is low or if the oil nozzle is partially blocked.

If the oil pressure is as expected and the inlet oil temperature is asexpected, than a higher tip temperature may indicate that the tip isinserted farther than design or that the flame is not where it isexpected to be (see below for an example). Therefore, it is clear thatthere is a complex interplay between the various measured parameters toascertain, for example, the reason for an elevated tip temperature or alower than expected oil pressure or a higher than expected oil pressure.Note that, in addition to comparing these parameters on each burner, forexample versus historical or predicted data, these parameters can alsobe compared across burners to detect abnormal operation of one of theburners and can be combined with other plant data. This determinationcan include a multi-variable analysis, for example as described in “ANew Paradigm in Real Time Asset Monitoring and Fault Diagnosis,” Neogi,D., et al., 2013 AIChE Annual Meeting, Conference ProceedingsPresentation No. 268b (Nov. 5, 2013).

In another example, a higher than expected oxidant pressure or increasedfluctuations in pressure may indicate a decrease in the oxidant flowarea in the burner block. For example, FIG. 15 shows data for oxidantpressure with and without an obstruction, and indicates that thepressure fluctuations with an obstruction are about 2 to about 6 timesthe magnitude of the pressure fluctuations without an obstruction. Inaddition, the average oxygen pressure is also higher with an obstructionthan without.

The expected oxidant pressure can be determined by other measuredvariables including flow control skid data. The oxidant pressure is afunction of oxidant flow (or to a first approximation, firing rate for aknown stoichiometry) and staging valve position as shown in FIG. 16. Byestimating the oxidant flow based on the measured oil pressure (assuminga clean oil nozzle) or natural gas pressure or from the method describedabove, there is an expected oxidant pressure based on the staging valveposition. To more accurately determine the expected oxidant pressure, itmay be useful to also determine the oxidant flow rate, for example viaan oxidant flowmeter or to infer the oxidant flow rate using the burnerfiring rate (which may be determined using previously described methods)and stoichiometry or by measuring the pressure drop across a known flowrestriction device 334 as shown in FIG. 11.

If the oxidant pressure is higher than the expected oxidant pressure,that could indicate that the flow area of the oxidant is decreasedeither due to blockage of the burner block openings or some otheropening. The burner block openings may be partially blocked by run downon the block face, slag, or other material that may have splashed ordripped onto the burner block. If such partial blockage occursundetected, it may lead to failure of the burner and/or burner block, soit is important to detect before such failure occurs.

In another example showing the affects of obstructions, FIG. 14 showsnatural gas and oxygen pressure in addition to burner nozzle tiptemperature, both with and without an obstruction near the hot face ofthe burner block. In this example, the obstruction was placed near thehot face of the burner block three different times, denoted as D4, D5,and D6. In each case the nozzle tip temperature decreased (an unexpectedresult considering that the burner flame was impinging on theobstruction at the block exit) and the natural gas pressure and oxidantpressure both increased.

In a similar example in FIG. 13, obstructions were placed near the hotface of the burner three different times at two different firing rates,denoted as D1 at a high firing rate FR1, and D2 and D3 at a lower firingrate FR2. When compared with FIG. 14, a similar result is seen for thefirst two obstructions D1 and D2, but for the third obstruction D3 thedetected nozzle tip temperature initially decreased and then increased.It has been noticed that the directional change of the nozzle tiptemperature is dependent on the operating conditions of the burner andthe furnace that is being fired into. Therefore it is advantageous touse more than one sensor to identify that there are obstructionsimpeding the normal operation of the burner.

In another example, one or more temperatures sensors mounted near theface of the burner block or near the gas flow path can be used to detectflame deflection, for example by comparing burner block temperaturesabove and below the exit of the oxidant and fuel, or to the left andright of the exit of the oxidant and fuel. These measurements may beparticularly useful with regard to the top (primary oxidant and fuel)exit as compared with the secondary oxidant exit. FIG. 18C showstemperature measurements in a burner block for a misaligned burnerfiring. In this example three thermocouples were embedded in the burnerblock positioned at three different distances from the block hot face:front, middle, and rear. The measured temperature increased for allthree locations when impingement began. The magnitude of the temperatureincreased was a function of the position of the actual flameimpingement, demonstrating the value of multiple temperaturemeasurements for positively identifying flame impingement in theincipient stages and as soon as possible.

In another example, the staging valve position by itself may be used todetermine that the burner settings are optimized and thatoperators/engineers are aware when something has changed on the burnersettings. Typically, the staging valve position is set during startup orcommissioning to optimize burner performance for the particular furnaceand process. The staging valve position would not normally be changedafter startup. However, sometimes a staging valve may be accidentally orintentionally turned to a non-optimal position, and it would beimportant to identify such a condition to ensure that the burner isoperating as desired.

In another example, the inlet oil temperature and possibly density maybe used to estimate the oil viscosity at the atomizing nozzle. Theviscosity is dependent on composition of the oil, so inlet oiltemperature by itself cannot determine the viscosity, but it can provideinformation about the viscosity especially when combined with the inletoil pressure (a function of the viscosity) and possibly density. Thiswill let an operator know if the inlet temperature is appropriate andwhen combined with the pressure data, possibly if the oil compositionhas changed.

In another example, position and angle sensors can provide informationabout the orientation of the burner and whether it is installedproperly, including whether the burner is level or at a desired slope orangle with respect to a furnace wall. For this purpose an accelerometer,gyroscope, or other device or combinations of devices can be used todetermine the installation angle of the burner or parts of the burner.Knowing the burner angle with respect to the burner wall, as well aspossibly other relevant angles that describe the position of the burnerand/or burner block (e.g., the angle of furnace wall, the burner block,a burner mounting device or devices) can be used to help determine ifthe burner is installed properly. Misalignment of the burner could causepremature burner or burner block failure. For example, as shown in FIG.17B, the angle of the burner with respect to the burner block andmounting plate was varied in both the pitch and roll directions, theburner was fired to check for flame impingement on the burner block. Asused herein, pitch indicates rotation about an axis perpendicular to thelongitudinal axis of the burner, so that the hot face the burner ispivoted up or down with respect to the rear of the burner; and rollindicates rotation about an axis coincident with the longitudinal axisof the burner, so that the plane of the burner face remains the same asthe burner is rotated about its axis (see FIG. 17A). When the burnernozzle was mounted parallel with the flow passage in the burner block,no flame impingement was seen. When the angle of the burner nozzle wasout of parallel by about 2 degrees flame impingement occurred.

In another example, monitoring may help optimizing operating conditionsof the burner to reduce pollutant formation such as nitrogen oxides(NOx) and to maximize flame quality by reducing or eliminating sooting.

The present invention is not to be limited in scope by the specificaspects or embodiments disclosed in the examples which are intended asillustrations of a few aspects of the invention and any embodiments thatare functionally equivalent are within the scope of this invention.Various modifications of the invention in addition to those shown anddescribed herein will become apparent to those skilled in the art andare intended to fall within the scope of the appended claims.

1. An oxy-fuel burner with monitoring, comprising: a fuel passageterminating in a fuel nozzle; a primary oxidant passage terminating inan oxidant nozzle; one or more sensors including: a nozzle temperaturesensor for sensing at least one of an oxidant nozzle temperature and afuel nozzle temperature; and a position sensor for sensing a burnerinstallation angle, the position sensor being configured to sense one ormore of a burner pitch and a burner roll; and a data processorprogrammed to receive data from the sensors and to determine based on atleast a portion of the received data the presence or absence of anabnormal burner condition including a potential partial obstruction ofat least one of the primary oxidant passage and the fuel passage basedon an increase or decrease in at least one of the oxidant nozzletemperature and the fuel nozzle temperature, and to determine whetherthe burner is installed at a desired orientation with respect to atleast one feature of the furnace based on the burner installation angle.2. The burner with monitoring of claim 1, wherein the data processor isprogrammed to base its determination at least in part upon changes in atleast a portion of the received data with time.
 3. The burner withmonitoring of claim 1, the one or more sensors further including anoxidant pressure sensor positioned in the primary oxidant passage forsensing a primary oxidant pressure; wherein the data processor isprogrammed to identify a potential partial obstruction of the primaryoxidant passage based on a change to the primary oxidant pressure and atleast one of the fuel nozzle temperature and the oxidant nozzletemperature.
 4. The burner with monitoring of claim 1, furthercomprising: a secondary oxidant passage spaced apart at a fixed distancefrom the primary oxidant passage; and a staging valve for proportioningoxidant between the primary and secondary oxidant passages; the one ormore sensors further including a staging valve position sensor forsensing a staging valve position as indicative of the relativeproportion of oxidant being directed to the primary and secondaryoxidant passages; wherein the data processor is further programmed todetermine the presence or absence of a partial obstruction of theprimary oxidant passage based on the staging valve position and at leastone of the fuel nozzle temperature and the oxidant nozzle temperature.5. The burner with monitoring of claim 1, further comprising: asecondary oxidant passage spaced apart at a fixed distance from theprimary oxidant passage; and a staging valve for proportioning oxidantbetween the primary and secondary oxidant passages; the one or moresensors further including: an oxidant pressure sensor for sensing anoxidant pressure at one or more of upstream of the staging valve,downstream of the staging valve in the primary oxidant passage, anddownstream of the staging valve in the secondary oxidant passage; and astaging valve position sensor for sensing a staging valve position asindicative of the relative proportion of oxidant being directed to theprimary and secondary oxidant passages; wherein the data processor isfurther programmed to determine the presence or absence of one or moreof a partial obstruction of one of the primary oxidant passage and thesecondary oxidant passage and a sub-optimal staging valve position basedon the staging valve position and the oxidant pressure at one or more ofupstream of the staging valve, downstream of the staging valve in theprimary oxidant passage, and downstream of the staging valve in thesecondary oxidant passage.
 6. The burner with monitoring of claim 5,further comprising: two pressure sensors, one positioned on either sideof a flow restriction device in at least one of the fuel passage, theprimary oxidant passage, and the secondary oxidant passage, for sensinga pressure upstream of the flow restriction device, a pressuredownstream of the flow restriction device, and a differential pressureacross the flow restriction device as indicative of flow rate; whereinthe data processor is further programmed to determine the presence orabsence of an abnormal burner condition based on the differentialpressure and one of the pressures upstream and downstream of the flowrestriction device.
 7. The burner with monitoring of claim 1, furthercomprising: a burner block having a hot face adjacent to the furnace;and a burner block temperature sensor for sensing a burner blocktemperature near the hot face; wherein the data processor is furtherprogrammed to determine the presence or absence of one or more of burnerblock overheating and flame asymmetry based on the burner blocktemperature.
 8. The burner with monitoring of claim 1, furthercomprising: a data collector programmed to provide power to individualsensors only when data is to be collected, based on one or both of acombination of sensed data and a periodic schedule, and taking intoaccount the specific requirements of each of the individual sensors; atransmitter for wirelessly transmitting sensor data from the datacollector to the data processor; and a local power generation system forpowering the data collector, the sensors, and the transmitter.
 9. Theburner with monitoring of claim 1, wherein the oxidant passage isannular and surrounds the fuel passage.
 10. A method of determining anoperating condition of an oxy-fuel burner including a fuel passageterminating in a fuel nozzle, a primary oxidant passage terminating inan oxidant nozzle, and a burner block having a face adjacent to thefurnace, the method comprising: sensing at least one of an oxidantnozzle temperature and a fuel nozzle temperature; sensing a burnerinstallation angle indicative of one or more of a burner pitch and aburner roll; comparing the at least one nozzle temperature to athreshold temperature; determining a potential partial obstruction ofone of the oxidant nozzle and fuel nozzle based on an increase ordecrease in the at least one nozzle temperature; and determining whetherthe burner is installed at a desired orientation with respect to atleast one feature of the furnace based on the burner installation angle.11. The method of claim 10, further comprising: sensing an oxidantpressure; determining a potential partial obstruction of the oxidantnozzle based on the oxidant pressure and the at least one nozzletemperature.
 12. The method of claim 10, the burner further including asecondary oxidant passage spaced apart at a fixed distance from theprimary oxidant passage and a staging valve for proportioning oxidantbetween the primary and secondary oxidant passages, the method furthercomprising: sensing an oxidant pressure at a location selected fromupstream of the staging valve, downstream of the staging valve in theprimary oxidant passage, and downstream of the staging valve in thesecondary oxidant passage; sensing a staging valve position indicatingthe proportion of oxidant being directed to the primary and secondaryoxidant passages; determining one or more of a potential partialobstruction of one of the primary oxidant passage and the secondaryoxidant passage and a sub-optimal staging valve position based on thestaging valve position and the oxidant pressure at one or more ofupstream of the staging valve, downstream of the staging valve in theprimary oxidant passage, and downstream of the staging valve in thesecondary oxidant passage.
 13. The method of claim 12, furthercomprising: sensing pressures at two locations, one on either side of aflow restriction device in at least one of the fuel passage, the primaryoxidant passage, and the secondary oxidant passage; determining a flowrate from the pressures at the two locations; and determining thepresence or absence of an abnormal burner condition based on the flowrate and the pressure of at least one of the two locations.
 14. Anoxy-fuel burner with monitoring, comprising: a primary first reactantpassage terminating in a first reactant nozzle; a primary secondreactant passage terminating in a second reactant nozzle; one or moresensors including a nozzle temperature sensor for sensing a nozzletemperature of at least one of the reactant nozzles; a position sensorfor sensing a burner installation angle, the position sensor beingconfigured to sense one or more of a burner pitch and a burner roll; anda data processor programmed to receive data from the sensors and todetermine based on at least a portion of the received data the presenceor absence of an abnormal burner condition including a potential partialobstruction of at least one of the primary first reactant passage andthe primary second reactant passage based on an increase or decrease inthe at least one nozzle temperature, and to determine whether the burneris installed at a desired orientation with respect to at least onefeature of the furnace based on the burner installation angle; whereinone of the first and second reactants is fuel and the other of the firstand second reactants is oxidant.
 15. The burner with monitoring of claim14, the one or more sensors further including a first reactant pressuresensor positioned in the primary first reactant passage for sensing aprimary first reactant pressure; wherein the data processor isprogrammed to identify a potential partial obstruction of the primaryfirst reactant passage based on a change to the first reactant pressureand the at least one nozzle temperature.
 16. The burner with monitoringof claim 14, further comprising: a secondary first reactant passagespaced apart at a fixed distance from the primary first reactantpassage; and a staging valve for proportioning the first reactantbetween the primary and secondary first reactant passages; the one ormore sensors further including a staging valve position sensor forsensing a staging valve position as indicative of the relativeproportion of the first reactant being directed to the primary andsecondary first reactant passages; wherein the data processor is furtherprogrammed to determine the presence or absence of a partial obstructionof the primary first reactant passage based on the staging valveposition and the at least one nozzle temperature.
 17. The burner withmonitoring of claim 14, further comprising: a secondary first reactantpassage spaced apart at a fixed distance from the primary first reactantpassage; and a staging valve for proportioning the first reactantbetween the primary and secondary first reactant passages; the one ormore sensors further including: a first reactant pressure sensor forsensing a first reactant pressure at one or more of upstream of thestaging valve, downstream of the staging valve in the primary firstreactant passage, and downstream of the staging valve in the secondaryfirst reactant passage; and a staging valve position sensor for sensinga staging valve position as indicative of the relative proportion of thefirst reactant being directed to the primary and secondary firstpassages; wherein the data processor is further programmed to determinethe presence or absence of one or more of a partial obstruction of oneof the primary first reactant passage and the secondary first reactantpassage and a sub-optimal staging valve position based on the stagingvalve position and the first reactant pressure at one or more ofupstream of the staging valve, downstream of the staging valve in theprimary first reactant passage, and downstream of the staging valve inthe secondary first reactant passage.
 18. The burner with monitoring ofany of claim 14, further comprising: a burner block having a hot faceadjacent to the furnace; and a burner block temperature sensor forsensing a burner block temperature near the hot face; wherein the dataprocessor is further programmed to determine the presence or absence ofone or more of burner block overheating and flame asymmetry based on theburner block temperature.